Theft-Resistant and Senior-Friendly Packaging of Consumer Products

ABSTRACT

The present invention is a novel, theft-resistant, and senior-friendly packaging for consumer and retail products that is cheap and easy to manufacture. The packaging is designed to prevent individuals from gaining access to the enclosed product through tampering with the packaging while at the same time meeting or exceeding federal child-resistant and senior-friendly guidelines. The packaging incorporates plastic material and multiple cuts to be tear-resistant and to halt the propagation of a tear, if one should occur.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 15/005,924, filed on Jan. 25, 2016, now U.S. Pat.No. 9,988,195, issued on Jun. 5, 2018, which is a continuationapplication of U.S. patent application Ser. No. 14/038,475, filed onSep. 26, 2013, now U.S. Pat. No. 9,242,777, issued on Jan. 26, 2016,which is a continuation application of U.S. patent application Ser. No.13/046,930, filed on Mar. 14, 2011, now U.S. Pat. No. 8,544,650, issuedon Oct. 1, 2013, which is a continuation of U.S. patent application Ser.No. 12/001,302, filed on Dec. 10, 2007, now U.S. Pat. No. 7,905,355,issued Mar. 15, 2011, which is a continuation-in-part of U.S. patentapplication Ser. No. 11/175,983, filed on Jul. 6, 2005, now U.S. Pat.No. 7,448,496, issued Nov. 11, 2008, which is a continuation-in-part ofU.S. patent application Ser. No. 10/799,199, filed on Mar. 12, 2004, nowU.S. Pat. No. 7,063,211, issued Jun. 20, 2006, which is acontinuation-in-part of U.S. patent application Ser. No. 10/394,495,filed on Mar. 20, 2003, now U.S. Pat. No. 7,188,728, issued Mar. 13,2007, and the foregoing applications are herein incorporated byreference in their entirety.

FIELD OF THE INVENTION

The present invention relates generally to an improved system and methodfor packaging consumer products. Specifically, the present inventionrelates to enhanced retail and consumer packaging designs thatincorporate tear resistant materials and tear-stop cuts into thepackaging. These tear resistant materials and cuts may be adapted toreduce theft, product tampering, or product degradation. In addition,the present invention relates generally to packaging designs thatfacilitate clean product dispensement, while at the same time increasingthe senior-friendly and child-resistant qualities of the package.

BACKGROUND OF THE INVENTION

One convenient form of retail packaging is blister card packaging.Blister card packages are commonly used for the distribution of manyretail and consumer products, including pharmaceutical drugs, batteries,sewing kits, toy cars, electronic and cellular accessories, personalcare products, hardware, tools, cosmetics, office supplies, and more.Blister card packaging provides an inexpensive, yet versatile form ofproduct distribution. Blister packaging, in its simplest form, comprisestwo vital components: a thermoformed blister and a paperboard blistercard. The thermoformed blister is typically a translucent chamber madeout of some variety of plastic (or other suitable material). The blisterhouses the product to be distributed using the blister packaging. Theblister card is the stiffener or backing sheet for the blister packagingand the product contained within the blister. Typically, the blistercard is comprised of pre-printed stiff paper, such as cardboard orpaperboard. Paperboard can include any product containing paper (or itsderivatives and blends) with a typical thickness of 10 points (0.25 mm)or more, layers of paper, laminated paper, or cardboard. The blistercard is usually folded to create at least two adjacent sides. One orboth of the sides typically contain an aperture. The product to bepackaged is usually encased within an individual blister, which may beinserted between the two adjacent sides of the blister card such thatthe product protrudes from one or both apertures. The flange area of theblister and the two blister card sides are then sealed, typically usinga blister machine. This machine introduces heat and pressure to theflange area of the blister, which may activate glue applied to theblister card. Ultimately, the individual blister is secured to theblister card, and the plastic blister is retained within its blistercard packaging.

Blister card packages may accommodate individual products in individualblisters (as described above) or may be designed to accommodate multipleproducts or multiple applications of a similar product. Typically,separate products or multiple applications of a similar product arehoused in blister strips or solid-form blisters. Small objects, such aspharmaceutical drugs, candy, and batteries, are often distributed inthis manner. A blister strip comprises a contiguous row of plasticblisters having a common backing, such as paper or foil. The commonbacking is usually one product unit wide by any number of product unitslong. In contrast, solid-form blisters comprise a matrix or grid of bothhorizontal and vertical rows of blisters. As with blister strips,solid-form blisters also typically share a common backing.

Many of the existing, patented blister card packages were originallydesigned for distribution of non-lethal pharmaceutical drugs. To sell toa larger market of users, these blister card packages were modified toachieve the federal testing guidelines for child-resistance using avariety of methods. These methods included adding paperboard layers,adding plastic or tape layers to the exterior of the paperboard,reinforcing a frangible foil backing with a less frangible paper, etc.As a result, many blister card packages exist today that have passedfederal child-resistant and senior-friendly testing guidelines.

After the aforementioned modifications were made, many blister cardpackages that were previously non-child-resistant were able to passchild resistance testing; however, the packaging became undesirable inseveral other ways. For example, the additional reinforced layers oftenprevented the product from being pushed cleanly through the blisterbacking. Specifically, some blister card package manufacturers added alayer of paper to the foil backing through which the product is pushed.This paper and/or foil backing does not tear cleanly. As a result, theuser has to scrape the backing until enough of the backing is removed toallow the user to grasp and peel the backing to reach the product. Thiscan be very difficult, especially for senior citizens or other adultswith impaired physical abilities.

Furthermore, once the backing is grasped and torn, a user can easilytear too much backing. This excessive tearing is undesirable, especiallywhen blister strips or solid-form blisters are used. The tearing may runinto an adjacent blister, allowing another product or item to beprematurely dispensed. Additionally, the user may not be able to scrapeenough backing to the point where the backing may be pulled away,causing the user to utilize a sharp object such as a knife or scissors.Cutting of the blister card packaging can lead to many more problems,including unintentional damage to the product, damage to the printedinstructions on the packaging, or injury to the person.

Alternatively, if a user cannot remove the reinforced layer of theblister backing and easily push the product through the non-reinforcedlayer of the blister backing, the user may attempt to force the productthrough the reinforced backing. This leads to at least two majorproblems. First, the content of the blister may be damaged and unusable.Second, the user may resort to bending the overall blister card packagecausing damage to the blister, the blister card, or the content of theblisters.

Conventional blister card packages also exhibit many other undesirablequalities. For example, the use of large blister card packages iscommonplace in the retail marketplace for displaying products for sale.These plastic blisters are often combined with a paperboard backingwhich allows the consumer to easily view the product through a clearpackage. These blister card packages are prone to theft and producttampering because the paperboard backing can easily be torn and the itemcontained therein can be effortlessly removed increasing opportunitiesfor theft and tampering of the item. In order to improve the theft andtamper resistance of the packages, blister card packages are availablewhich are composed entirely of heavy gauge plastic. Such packages arecommonly used for consumer products, such as compact discs, computerdevices and peripherals, household electronics, etc. These heavy gaugeplastic blisters are extremely inconvenient because they usually requiretools, such as knives or scissors, and a large amount of physicalstrength to open the blister and access the product. In addition, theseheavy gauge plastic blisters cannot be directly printed on, which makesthem less attractive and offers less marketing potential for vendors.

There are various techniques which can currently be employed to producepaperboards which are tear resistant or tear proof. The existingtechnology in the field consists of paperboard sheets which have aplastic material applied onto one side to produce a tear resistantmaterial. The plastic material is extruded or laminated onto the sheetof paperboard. It is the laminate material, not the paperboard, whichprovides the resistance to tearing. However, such tear-proof paperboardoften exhibits small nicks or cuts in the edge of the paperboard due tomanufacturing, transport, and handling. These nicks and cuts oftenbecome a starting point for a tear, and depending on the material of thelaminate, once a tear is started it can be easily continued. While suchtear-proof paperboard technology can improve the theft resistance ofblister card packages, they are still prone to theft and producttampering. In addition, the effectiveness of the tear resistance isdiminished because a small tear or nick in the edge of a sheet can leadto the total failure of the tear-resistant material due to thepropagation of the tear.

By way of example, the general state of the art of blister card packagesis defined by Compere U.S. Pat. No. 3,809,221 (hereinafter referred toas “Compere”), Davie, Jr. et al. U.S. Pat. No. 4,125,190 (hereinafterreferred to as “Davie”), Dlugosz U.S. Pat. No. 4,506,789 (hereinafterreferred to as “Dlugosz”), Intini U.S. Pat. No. 4,537,312 (hereinafterreferred to as “the Intini '312 patent”), Intini U.S. Pat. No. 4,988,004(hereinafter referred to as “the Intini '004 patent”), Wharton et al.U.S. Pat. No. 5,172,812 (hereinafter referred to as “Wharton”), Bitneret al. U.S. Pat. No. 5,310,060 (hereinafter referred to as “Bitner”),Sowden U.S. Pat. No. 5,325,968 (hereinafter referred to as “Sowden”),Price U.S. Pat. No. 5,339,960 (hereinafter referred to as “Price”),Matthews et al. U.S. Pat. No. 5,469,968 (hereinafter referred to as“Matthews”), Leblong U.S. Pat. No. 5,758,774 (hereinafter referred to as“Leblong”), Vasquez et al. U.S. Pat. No. 5,775,505 (hereinafter referredto as “Vasquez”), Dressel et al. U.S. Pat. No. 5,785,180 (hereinafterreferred to as “Dressel”), Plezia et al. U.S. Pat. No. 5,862,915(hereinafter referred to as “Plezia”), Faughey et al. U.S. Pat. No.5,878,888 (hereinafter referred to as “the Faughey '888 patent”),Faughey et al. U.S. Pat. No. 5,894,930 (hereinafter referred to as “theFaughey '930 patent”), Godfrey et al. U.S. Pat. No. 5,927,500(hereinafter referred to as “Godfrey”), Ray et al. U.S. Pat. No.5,944,191 (hereinafter referred to as “Ray”), Gartland U.S. Pat. No.6,161,699 (hereinafter referred to as “Gartland”), Danville U.S. Pat.No. 6,338,407 B2 (hereinafter referred to as “Danville”), and SwartzU.S. Pat. No. 6,422,391 B1 (hereinafter referred to as “Swartz”).

Compere, the Intini '312 patent, Wharton, Price, and Dressel disclosechild-resistant blister card packaging having two layers covering theopening to each blister. To access the product contained within theblister, the user first peels an outer non-frangible layer, such asstiff paper, to expose an underlying frangible layer, such as thin foil.The underlying frangible layer comprises a material that allows the userto push the product contained within the blister through the frangiblelayer. This type of packaging is referred to as peel-push.

Many problems exist with peel-push blister card packaging. One suchproblem is the difficulty involved with grasping the outer layer so thatit may be peeled. Since many outer layers are difficult to grasp, userstend to bend the overall packaging or use sharp objects to remove theouter layer. This results in damage to the packaging or to the productsthemselves. In particular, some of these outer layers are so difficultto grasp that senior citizens or other adults suffering from diminishedphysical abilities or poor eyesight may not be able to access theblister product without assistance. Also, the damage to the packagingreduces or frequently eliminates its child resistance.

Another problem with peel-push packaging is evident in blister packagescontaining multiple products or applications. In these packages, even ifthe user is able to grasp the outer layer, the user often removes toomuch of the outer layer, thereby accessing adjacent products. Therefore,the frangible layer of other adjacent products that the user does notintend to remove is exposed. Again, this problem causes the childresistance of the adjacent product to be reduced or totally eliminated.Furthermore, the blister card packaging does not have any means ofreducing theft or product tampering.

Davie also discloses peel-push blister card packaging. However, toremove the content of the blister as disclosed in Davie, the user peelsaway a tear strip that exposes the frangible foil backings of an entirerow of blisters. After the tear strip is removed, the user may push thecontent of any blister in the row through its respective foil backing.The blister card packaging disclosed in Davie suffers the samelimitations as other peel-push packaging. Namely, the outer layer isdifficult to grasp prior to peeling. In addition, the Davie product isactually designed to expose the frangible layer of products that are notready to be removed. This aspect obviously diminishes the childresistant capabilities of the unopened package. Also, the Davie productcontains no means to deter theft or product tampering.

Dlugosz also discloses a peel-push blister card package; however,Dlugosz discloses a method that requires the user to first bend thepackage. The blister card package disclosed in Dlugosz comprises apaperboard sheet folded to create two adjacent paperboard sheets. Theblisters are inserted between the two adjacent paperboard sheets andcontain a frangible backing through which the user may push the contentof the blister. To expose the frangible backing, the user removes a tearstrip located on one of the paperboard sheets. The user grasps the tearstrip by bending the edge of the paperboard to access a leading tab,which assists in the removal of the tear strip. Although Dlugoszdiscloses a better method of grasping the tear strip, Dlugosz stillrequires the bending of the packaging. Also, Dlugosz does not disclose amethod that prevents the user from tearing more of the backing thannecessary to expose the frangible layer of the desired product. Finally,the tear strip may still be difficult to grasp for senior citizens orother adults suffering from diminished physical abilities. Furthermore,Dlugosz does not disclose any means for reducing theft or producttampering.

Similar to Dlugosz, the Intini '004 patent discloses a blister cardpackage that requires the user to perform a “bend-peel-push” method toremove the content. First, the user bends the entire blister cardpackage to expose a pull-tab. Then, the pull-tab may be used to peelaway the outer layer of the card such that only the frangible layerremains. The content of the blister may then be pushed through thefrangible layer. Although the Intini '004 patent discloses a bettermethod of grasping the outer non-frangible layer, the Intini '004 patentstill requires the user to bend the packaging. This may be difficult forfrail adults, especially those suffering from an ailment such asarthritis. Furthermore, because the Intini '004 patent requires bothfoil and paper frangible layers, it is difficult to push the productthrough the two frangible layers. Furthermore, seniors have a moredifficult time pressing products through the thicker frangible layers.Again, the product does not have any theft resistance means.

Bitner discloses a blister card package that requires a user to break aT-shaped perforation to access a corner of a non-frangible layer. Thenon-frangible layer may then be peeled away to expose the frangiblelayer. Subsequently, the user may push the content of the blisterthrough the frangible layer. Although the additional layer containingthe T-shaped perforation may provide a higher child resistance rating,the additional layer adds another level of complexity for those userswho suffer from diminished physical abilities or poor eyesight. Also,Bitner does not disclose any theft resistance means for the blister cardpackage.

Sowden discloses a blister card package that requires the user toperform multiple steps to remove the content of the blister. Initially,the user must remove a single blister from a solid form blister. Next,the user peels a first strip from the single blister. Once the firstpeelable strip is removed, a depression is exposed that allows the userto peel away the backing of the blister, thereby gaining access to thecontent of the blister. Similar to the packaging disclosed in Bitner,although the additional complexity required to access the content of theblister might achieve a higher child resistance rating, the additionalcomplexity also makes the content of the blister less accessible tothose users who suffer from diminished physical abilities or pooreyesight. Also, the Sowden product does not have any means to detertheft or product tampering.

Matthews discloses a blister card packaging comprising three distinctlayers. The first, innermost layer is frangible, and the second andthird outer layers are non-frangible. The second and third layers areperforated in two distinct patterns. Therefore, the user initiallyremoves the third (outermost) layer according to its perforationpattern. Then, the second layer is removed according to its distinctperforation pattern. Finally, the content can be pushed through theinnermost frangible layer. The packaging disclosed in Matthews suffersfrom the same limitations as the aforementioned packaging containing twodistinct layers. Namely, there is an additional level of complexityrequired to access the product, and the possibility exists for the userto tear more of the backing than required. As a result, the childresistant properties of the packaging of the remaining products arereduced. However, these limitations are magnified by the addition of athird layer, i.e., the outermost non-frangible layer. Furthermore, theblister card packaging does not have any means of reducing theft orproduct tampering.

Vasquez discloses a blister card package that requires a user to removean individual blister from a solid-form blister via perforations in thenon-frangible layer. Once the individual blister has been isolated fromthe solid form blister, a pull-tab is exposed on the corner of thebacking of the individual blister. The user then pulls the pull-tab topeel away the backing and access the content of the blister. Again, theVasquez packaging requires multiple, intricate steps that will bedifficult to perform by users suffering from diminished physicalabilities or poor eyesight. Also, the Vasquez product does not have anymeans to deter theft or product tampering.

Leblong discloses a blister card package that requires the user to tearaway two strips before accessing the content of a blister. The firststrip is formed on the edge of a solid-form blister. Once the firststrip is torn away, multiple pull-tabs form a series of secondary stripsare exposed. The user may then pull away an individual secondary stripby pulling the respective pull-tab, thereby exposing a frangible layercovering a row of blisters. Thereafter, similar to Davie, the content ofany blister in the row may be removed by pushing the content of theblister through the frangible layer, which reduces the package's childresistance. Furthermore, Leblong does not disclose any means forreducing theft or product tampering.

Plezia, the Faughey '888 patent, the Faughey '930 patent, and Raydisclose blister card packages that require the user to press on aspecified area of the blister card package to create a pull tab.Thereafter, the pull-tab may be pulled to remove the backing from theblister and expose the blister content. However, none of these patentsdisclose a method that prevents the user from removing more of thebacking than that which covers the intended blister or blisters to bedispensed. In addition, although the pull-tab facilitates removal of theblister backing for an adult, the pull-tab also reduces the package'schild resistance by facilitating removal of the blister backing by achild. Again, the product does not have any theft resistance qualities.

Godfrey discloses a folded blister card package that encloses a blister,blister strip, or solid-form blister. The side of the folded blistercard that faces the blister backings comprises a series of ovalperforations. To eject the content of a blister, the user simply pressesthe top of the blister forcing the content of the blister through thefoil backing and the respective oval perforation, causing a hole to formin the blister card packaging through which the content of the blistermay pass. If the rigidity of the perforated ovals is low, the packagingdisclosed in Godfrey allows a child to have easy access to the contentof the blister. In contrast, if the rigidity of the perforated ovals ishigh, the Godfrey packaging impedes access to the content of the blisterfor adults having impaired physical abilities. Also, Godfrey does notdisclose any theft resistance means for the blister card package.

Similar to Godfrey, Gartland also discloses a blister card packagecomprising a series of perforated ovals; however, Gartland discloses alayer of plastic biaxial film that covers the perforated ovals. Toremove the perforated ovals, the user must first peel the plasticbiaxial film from the ovals. The perforated ovals can then be removedsuch that the foil backing of the blisters are exposed. The user thenpushes on an individual blister to force the blister content through theblister backing. These three steps can be very difficult for a seniorcitizen or other adult with impaired physical abilities. Suchindividuals may resort to sharp objects for removal of any of theaforementioned layers, which is likely to damage the packaging orproduct contained within the packaging. Also, the Gartland product doesnot have any means to deter theft or product tampering.

Danville discloses blister card packaging that also requires the user toperform a series of steps to access the blisters' content. First, theuser must remove a group of blisters by pushing the group through aperforated section of the blister card package. Once the blister groupis removed from the blister card package, a second perforation isexposed. The user then accesses the second perforation to grab and tearthe packaging in the area adjacent to the desired blister. Along thetear, there is an area wherein the portion of the backing being torn andthe underlying backing are not adhered together. At this location, thelayers may be easily separated allowing the innermost backing to beeasily peeled away from the blister. Whereas the lack of adhesionbetween the outer and inner layers of the backing facilitates removal ofthe backing, the multiple peels required to remove the blister's contentrenders the Danville packaging difficult for adults having impairedphysical abilities. Furthermore, the blister card packaging does nothave any means of reducing theft or product tampering.

Finally, Swartz provides a blister card package that requires the userto tear the blister card package in two directions. Prior to tearing theblister card package, the user must remove a blister segment via aperforated section of the blister card package. Each blister segmentcomprises two lines cut in the blister segment backing such that the twolines merge on one side of the backing and are separated on the otherside of the backing. Therefore, by pushing between these two lines atthe point where the two lines merge, the user may create a pull-tab thatmay be used to begin tearing the segment backing. Finally, to access thecontent of the desired blister, the user continues to tear thepreviously torn backing in the direction of the desired blister. Theblister card packaging disclosed in Swartz does not contain a method ofpreventing more than the desired backing from being torn. Additionally,the pressure exerted on the packaging to form the pull-tab may damagethe packaging. Also, the Swartz product does not have any means to detertheft or product tampering.

Thus, there is a clear need for retail and consumer packaging thatincorporates means for reducing theft, product tampering, and productdegradation when the packaging is displayed for customers to handle atretail locations. In addition, a clear need exists for an improved formof packaging that is also child-resistant and senior-friendly. There isalso a clear need for a tear resistant blister card packaging thatcontains two types of cuts, which allows for the content of theindividual blister to be cleanly pushed through a non-frangible layerwithout bending the entire blister card packaging or disrupting adjacentblisters.

SUMMARY OF THE INVENTION

One object of the present invention is to provide an improvedtheft-resistant blister card package particularly suited for thedistribution of retail and consumer products. The blister card packageof the present invention is designed to increase the level of theft andtamper resistance by preventing tears in the paperboard which couldresult in failure of the package and improper dispensement of theproduct. In addition, the blister card package halts existing tears toavoid further damage to the blister package. Additionally, the blistercard package of the present invention allows an item to be removedcleanly from its individual blister without damage to the blister cardpackage or the item contained in the blister card package. Furthermore,each item may be removed without degrading the child resistance of theblister card packaging enclosing the remaining items, if any.

It is another object of the present invention to provide other enhancedretail and consumer product packaging systems and methods in addition toblister card packaging that incorporate the same theft-resistant,tear-resistant, and senior-friendly qualities. These forms of packagingmay similarly reduce product tampering and ensure product integrity.

The blister card package of the present invention is used to encase anindividual blister, blister strip, or solid-form blister as describedabove. After one or more of the blister segments are inserted into theblister card package, the blister card package is sealed around theblister segment, typically via the application of pressure and heat. Theblister card package and contained blister segment(s) are thendistributed to individual users. The user accesses the content of theindividual blister by, for example, cutting portions of the package,tearing along pre-defined perforations, using a push-peel-push method orpushing the contents of the individual blister through the non-frangiblelayer of the package, as described in the instructions printed on thepaperboard of the blister card package, or other like methods of access.

For example, in the push-pull-push method, the user pushes aspecially-marked, color-coded target area with an object, such as a pen,fingernail or a specially designed tool, which may be provided with theblister card package, to form a pull tab. The use of a tool to create apull-tab minimizes the physical strength required by the user. It has awide base for holding the tool and a small end for pushing the targetarea on the blister card. The color-coded target area facilitates usefor those suffering from diminished eyesight. Additionally, pushing thetool through a specially marked target area that is separate from theindividual blister, as compared to bending the blister card package orpushing the individual blister, prevents damage to the blister cardpackage and its contents and also maintains the child-resistance of thepackaging.

Each individual blister has an associated target area and die-cut portalor blister panel. Pushing the specially marked target area causes thedie-cut portal in the paperboard backing (i.e., the backing thatreinforces the foil backing of the blister segment) to break away fromthe remainder of the paperboard backing. The pushed portion of thedie-cut portal forms a tab that may be used to peel the remainder of thedie-cut portal from the paperboard backing, thereby exposing thefrangible layer covering the individual blister opening. Due to theunique manufacturing method of the blister card package the die-cutportal is removed completely and easily without removing any of thepaperboard surrounding the die-cut portal, thereby maintaining the childresistance rating and the structural integrity of the blister cardpackage. Finally, the content of the designated individual blister maybe pushed through the frangible backing.

In another example, the user may apply pressure directly on the blister,which essentially pushes the contents of the blister through anon-frangible layer containing two types of cuts. These two types ofcuts consist of a score-cut and a perforated cut. The design of thenon-frangible layer also known as the rear card is novel because itcontains a perforated cut, which completely penetrates the rear card,and a score-cut, which only partially penetrates the rear card. Thisdesign of the rear card is what allows a user to cleanly push thecontents of the blister safely through the non-frangible rear cardwithout accidentally releasing the contents of the remaining blisters orbending and damaging the entire blister card package. Additionally,since the backing of the blister card package (rear card) is resilientand sturdy the product remains both theft-resistant and child-resistantwhile maintaining its senior-friendly characteristics. What is importantto notice is that this method does not require a user to push aspecially-marked target area and therefore a pull-tab is no longerrequired as previously discussed in the push-pull-push method.

To manufacture the blister card of the present invention, a single sheetor multiple sheets of a material such as paperboard, cardboard, oranother similar material may be used. For exemplary purposes,manufacturing with a single sheet of paperboard is described.

First, the paperboard sheet is cut. The cut of the sheet is based partlyon the specifications of the items to be packaged, i.e., the retail itempre-packaged in 4.times.4 solid form blisters, and partly on the blistercard manufacturer's method of achieving child-resistant, senior-friendlystandards and theft resistance. In the preferred embodiment, a laminatedtear-resistant film is applied to the back side of the paperboard,opposite the finished/smooth surface for printing. Preferably, thetear-resistant layer is polyester, but the layer could comprise anysimilar tear-resistant layer of material, such as any variety of polymeror plastic.

Although a tear-resistant layer is used to prevent the starting pointsof a tear, any break, cut, nick, or deformity in the edge of thepaperboard can effect the initiation and continuation of a tear.Specifically, during manufacturing of a child resistant heat sealblister card, it is likely that some portion of the outer edge of theblister card may develop areas of degradation, including bends, nicks,or breaks, which can allow for the initiation of a tear. The tear mayeventually propagate to the product-containing blister and eventually tothe product itself.

The blister card package of the present invention is designed to haltthe propagation of a tear in the tear-resistant material or cardboardbacking if it should occur. This is accomplished by applying a clean andunbroken “tear-stop” cut to the paperboard which fully penetrates thethickness of the tear-resistant laminate film but does not fullypenetrate through the paperboard. This eliminates the possibility oftear initiation points and propagation beyond the tear-stop cut. In thepreferred embodiment, the tear-stop cut is added to the paperboardapproximately ¼ inch to ½ inch inside of all of the cut edges of thecard. However, the tear-stop cut may be placed closer or farther fromthe outside edge as desired. Therefore, a tear, if it is initiated fromthe outer edge of the sealed card, is prevented from running through thetear-stop cut.

Alternatively, a tear-stop cut may also be placed around each of theindividual blister targets, or any convenient location that would haltthe continuation of a tear in the paperboard. In the preferredembodiment, the tear-stop cut is applied to all perimeters of the card,maintaining the tear resistance of the laminated paperboard. Thus, it isdifficult to access the product by tearing the heat seal child-resistantblister card from the edges of the card.

The child-resistant and senior-friendly attributes of the presentinvention are created by one distinct cut per blister on the front cardand a unique bi-level cut on the rear card. The front card is theportion of the paperboard sheet that will be placed on top of theblisters and the rear card is the portion of the paperboard sheet placedbehind the foil backing of the blister segment. The distinct cut inevery individual blister on the front card provides an aperture throughwhich the individual blister is placed. The bi-level cut on the rearcard includes one perforated cut, which completely penetrates thepaperboard, and one cut-score, which partially penetrates thepaperboard. In the preferred embodiment of the present invention, theperforated cut comprises an oval that surrounds the blister opening, andis associated with the blister. The cut-score is also oval, but slightlysmaller than the perforated cut.

The cut score is located on the interior of the blister card package tofacilitate a clean tear of the die-cut portal, which is attached to therear card by the perforated cut. Therefore, the cut score does notfacilitate a clean tear if the user presses from the back of the packageor does not follow instructions. For example, it will be very difficultfor a child playing with the package to tear the portal from theexterior of the package or an individual to remove the content of thepackage in an attempt to steal the contents without using a tool todamage the die-cut portal or using a device to cut through the blisterpack. Additionally, the length and size of the cuts and landings (i.e.,the intact portions between the cuts that form the die-cut portal) canbe varied to regulate the difficulty with which the die-cut portal isremoved.

It is an object of the present invention to provide cost effectivepackaging that is difficult for a person to manipulate for the purposeof theft or product tampering.

It is also an object of the present invention to provide improvedblister card packaging that is difficult to open by means of tamperingwith the packaging.

Furthermore, it is an object of the present invention to prevent a tearin the packaging material of a consumer product and to halt thepropagation of a tear if one should occur.

Additionally, it is an object of the present invention to providepackaging that is easily accessible to competent adults and seniorcitizens, including those with impaired physical abilities.

It is also an object of the present invention to provide blisterpackaging that is easily and inexpensively manufactured.

Further, it is an object of the present invention to provide blistercard packaging that allows an individual blister's contents to be easilyand cleanly removed without damage to the blister card package, theblister contents, or the blister backings.

In addition, it is an object of the present invention to provide blistercard packaging that allows text, images, patterns, designs, and othermarketing material to be printed on the packaging.

It is yet another object of the present invention to provide blistercard packaging that allows instructions to be printed on the packaging.

Additionally, it is an object of the present invention to providepackaging other than blister packaging that incorporates tear-resistantmaterial in the packaging.

Other objects, features, and characteristics of the present invention,as well as the methods of operation and functions of the relatedelements of the structure, and the combination of parts and economies ofmanufacture, will become more apparent upon consideration of thefollowing detailed description with reference to the accompanyingdrawings, all of which form a part of this specification.

BRIEF DESCRIPTION OF THE DRAWINGS

A further understanding of the present invention can be obtained byreference to a preferred embodiment, along with some alternativeembodiments, set forth in the illustrations of the accompanyingdrawings. Although the illustrated embodiments are merely exemplary ofsystems for carrying out the present invention, both the organizationand method of operation of the invention, in general, together withfurther objectives and advantages thereof, may be more easily understoodby reference to the drawings and the following description. The drawingsare not intended to limit the scope of this invention, which is setforth with particularity in the claims as appended or as subsequentlyamended, but merely to clarify and exemplify the invention.

For a more complete understanding of the present invention, reference isnow made to the following drawings in which:

FIG. 1A depicts a front schematic view of a single strip blister card inaccordance with the preferred embodiment of the present invention.

FIG. 1B depicts a rear schematic view of the single strip blister cardof FIG. 1A in accordance with the preferred embodiment of the presentinvention;

FIG. 1C depicts a side cross-sectional view of the single strip blistercard of FIG. 1A in accordance with the preferred embodiment of thepresent invention;

FIG. 2A depicts a front schematic view of the front card of amulti-strip blister card package in accordance with the preferredembodiment of the present invention;

FIG. 2B depicts a rear schematic view of the front card of themulti-strip blister card package in accordance with the preferredembodiment of the present invention;

FIG. 2C depicts a front schematic view of the rear card of themulti-strip blister card package in accordance with the preferredembodiment of the present invention;

FIG. 2D depicts a rear schematic view of the rear card of themulti-strip blister card package in accordance with the preferredembodiment of the present invention;

FIG. 2E depicts a magnified view of the die-cut portal, cut-score, andthe perforated cut of the rear card of FIG. 2C;

FIG. 3A depicts an exploded side view of the front card of FIG. 2A andrear card of FIG. 2C of the multi-strip blister card package inaccordance with the preferred embodiment of the present invention andthe blister card prior to assembly in accordance with the preferredembodiment of the present invention;

FIG. 3B depicts a side view of the assembled front card, rear card, andblister card of FIG. 3A to create a blister card package in accordancewith the preferred embodiment of the present invention;

FIG. 3C depicts an exploded side view of the blister card of FIG. 1A andrear card of FIG. 2C of the multi-strip blister card package inaccordance with the preferred embodiment of the present invention andthe blister card prior to assembly in accordance with the preferredembodiment of the present invention;

FIG. 3D depicts a side view of the assembled blister card and rear cardof FIG. 3C to create a blister card package in accordance with thepreferred embodiment of the present invention;

FIG. 4 depicts a front schematic view of the assembled blister cardpackage of FIGS. 2A-3B in accordance with the preferred embodiment ofthe present invention;

FIG. 5 depicts a front schematic view of an unfolded blister cardpackage of the preferred embodiment of the present invention having afoldable front cover comprising printed instructions, dosageinformation, and content information;

FIG. 6 depicts a front schematic view of a solid form blister inaccordance with an alternate embodiment of the present invention;

FIG. 7 depicts an alternate embodiment of the present invention adaptedfor use with security, audit, RFID, or consumer product tags;

FIG. 8A depicts a schematic view of a foldable blister card inaccordance with an alternate embodiment of the present invention adaptedfor consumer electronics products;

FIG. 8B depicts a front schematic view of the assembled blister card ofFIG. 8A;

FIG. 9A depicts a schematic view of a foldable package card inaccordance with an alternate embodiment of the present invention adaptedfor consumer postal products;

FIG. 9B depicts a front schematic view of the assembled package card ofFIG. 9A;

FIG. 10A depicts a front schematic view of a blister package inaccordance with an alternate embodiment of the present invention adaptedfor small retail products; and

FIG. 10B depicts a rear schematic view of the front blister card of FIG.10A.

DETAILED DESCRIPTION OF THE INVENTION

Detailed illustrative embodiments of the present invention are disclosedherein. However, techniques, systems and operating structures inaccordance with the present invention may be embodied in a wide varietyof forms and modes, some of which may be quite different from those inthe disclosed embodiments. Consequently, the specific structural andfunctional details disclosed herein are merely representative, yet inthat regard, they are deemed to afford the best embodiments for purposesof disclosure and to provide a basis for the claims herein which definethe scope of the present invention. The following presents a detaileddescription of a preferred embodiment (as well as some alternativeembodiments) of the present invention.

FIG. 1A depicts a front schematic view of a blister card in accordancewith the preferred embodiment of the present invention. Blister card 100comprises base 101, which is preferably thermoformed from a flexible,semi-rigid plastic. However, base 101 may be constructed from variousother materials including, for example, injected mold plastics, thickfoil, polyvinyl chloride (PVC), polyvinyl dichloride (PVdC), Aclar,polypropylene (PP), etc. Blister 102 of blister card 100 is abubble-type portion that is typically manufactured of the same materialas base 101. Blister 102 protrudes from base 101 forming a cavitywherein a product may be stored. FIG. 1A illustrates blister 102containing product 103. As depicted, product 103 is of an elongated ovalshape, which is commonly associated with a pharmaceutical-type medicinedosage. However, this type of product is shown for exemplary purposesonly and other types of retail products may be utilized in accordancewith the present invention. For example, product 103 may include suchitems as machinery parts, tools, hardware, personal care products,consumer electronics, toy cars, sewing kits, or any other product thatmay be stored within a blister-type enclosure. Also, the presentinvention may utilize cold-form blisters, or blisters that are formedfrom two sheets of foil such that a first sheet forms one or moreblisters and a second sheet forms the blister seals. In accordance withthe present invention, cold-form blister foils are typically made fromlayers of various materials, including aluminum, biaxally orientatedpolyamide (OPA), and PVC, but any suitable materials may be used.

Turning to FIG. 1B, depicted is a rear schematic view of blister card100, which illustrates backing 105. Portions of backing 105 act as seal104 for sealing the openings of blister 102. Backing 105 is preferablyconstructed from aluminum foil. However, other types of foil, films, orother materials such as paper and plastic may be used. Additionally,backing 105 may comprise perforations or cut-scores surrounding portionsof the backing. These portions may overlap, follow, or coincide with theperimeter of the blister opening, i.e., seal 104. The perforations orcut-scores may be designed to assist the user in penetrating the portionof backing 105 that acts as seal 104.

FIG. 1C depicts a side view of blister card 100. A user can easilyremove product 103 from blister 102 by pushing downward (with respect tothe horizontal plane) on blister 102 such that product 103 ruptures ordisplaces seal 104. Preferably, seal 104 of blister card 100 isfrangible to prevent damage to product 103 or other content of blister102 when the content is pushed through the frangible layer. Blister 102is preferably constructed from a tear and puncture resistant, durable,flexible, semi-rigid material, thus allowing the user to push on blister102 forcing product 103 through seal 104 while preventing breakage ofproduct 103. Further, blister 102 may be formed as an indentation inbase 101 or may be constructed from a different material that is adheredto base 101.

As shown in FIGS. 2A, 2B, 2C, and 2D, the blister card package of thepreferred embodiment of the present invention is constructed from frontcard 201 (FIGS. 2A and 2B) and rear card 230 (FIGS. 2C and 2D). Frontcard 201 of FIG. 2A comprises at least one oval aperture 202. Ovalaperture 202 is adapted to fit a blister, which is placed through ovalaperture 202.

In the preferred embodiment of the present invention, the paperboardused to create front card 201 has one side that is laminated andpre-coated with a heat-activated adhesive. Purchasing paperboard withpre-applied adhesive reduces the cost of manufacturing. The paperboardof front card 201 is configured such that the rear of front card 201 iscoated with the adhesive. Although the preferred embodiment of thepresent invention uses an adhesive activated by heat, other adhesivesincluding an adhesive activated by some other means (such as pressure)may also be used. Alternatively, front card 201 can be fabricatedwithout adhesive, whereupon adhesive is applied during the assemblyprocess, or a method other than adhesion may be utilized to assemble theblister card package (e.g., crimping, pressure sealing, fusion,fastening, etc.).

For exemplary purposes, front card 201 comprises oval aperture 202.However, any configuration or any number of apertures is contemplatedwithout departing from the spirit of the present invention. In fact, thepresent invention may utilize irregular, custom, or genericarrangements. Additionally, the design employed by the present inventioncan accommodate a large volume of oval apertures 202 (or any other shapeof aperture) in many various arrangements, thereby making the presentinvention suitable for various retail, consumer and pharmaceuticalproducts.

An exposed rear view of front card 201 is depicted in FIG. 2B. In thepreferred embodiment, the rear side of front card 201 is laminated witha tear resistant plastic film 204, such as polyester. However, any typeof tear-resistant material such as polyethylene or polypropylene may beused to create a film. Alternatively, either side of the paperboard maybe completely or partially laminated. The laminated material increasesthe level of theft resistance by making the paperboard highly resistantto tears. Furthermore, the tear resistance of laminated paperboard canbe significantly increased by the addition of a “tear-stop” cut. Thetear-stop is a cut applied to the laminated side of the tear-resistantpaperboard. A clean, unbroken cut approximately one-quarter inch toone-half inch inside all of the perimeter edges of the card formstear-stop cut 205. Of course, it is contemplated that the tear-stop maybe placed at any point along the paperboard while still performing thefunctionality of stopping the propagation of side tears. The tear-stopcut fully penetrates the thickness of tear resistant film 204 but doesnot fully penetrate through the paperboard. Therefore, if a tear isinitiated from the outer edge of the sealed card, the tear will notreadily continue and run through or beyond tear-stop cut 205. As shown,tear-stop cut 205 may be applied to all perimeters of the card. Thetear-stop cut may be placed at any distance from the outer edge of thepaperboard and in any arrangement.

A laminated paperboard is highly tear resistant where there are no nicksor cuts along the edge of the paperboard. However, it is very difficultto manufacture a product made from the laminated material withoutcreating small imperfections along the edge of the product. An object ofthis invention is to create a second edge, a new tear-stop edge, withfewer or no nicks or cuts so that the propagation of tears iseliminated. It is also contemplated that multiple tear-stops can becreated within the same product. This layering of tear-stops wouldfurther increase the tear resistance of the card.

If a person were to attempt to tear the laminated paperboard from theedge and was successful in beginning a tear, they would quickly arriveat the tear-stop of the laminate and be prevented from tearing across,through, or beyond the remainder of the package. This method ofincreasing the tear resistance of paperboard materials will be importantfor improving the child resistance, tamper resistance, and theftresistance of retail products. When an improved tear-resistantpaperboard is used in conjunction with a blister card package or otherretail package for a consumer product, the ability to easily pilfer theproduct from the package is greatly diminished. For example, a thief ina retail location can easily tear a 2 inch cubic cardboard box andobtain the small item inside in an attempt to take the small item. Toremedy this, the small item may be packaged in a large (e.g., a 12 inch)reinforced paperboard blister pack utilizing at least one tear-cut. Athief capable of creating a first tear may be further defeated by thetear-cut, which prevents the tear from proceeding. To overcome thetear-cut, the thief must expend time and effort to create another newtear. Although rigid plastic packaging known in the art acts as adeterrent in this manner, the present invention allows for the novel useof the tear-cut to further enhance the tear resistance. In addition,this method still provides for a surface that the retailer can utilizeto market the product (e.g., a retailer can market the product byprinting graphics on the paperboard blister that could not be easilyprinted on the rigid plastic surfaces commonly utilized).

Front and rear views of rear card 230 are illustrated in FIGS. 2C and2D, respectively. For the preferred embodiment of the present invention,rear card 230 is fabricated from paperboard purchased with aheat-activated adhesive pre-applied to one side of the paperboard,again, to reduce the cost of manufacturing. The paperboard of rear card230 is positioned such that the front of rear card 230 contains adhesiveand the rear of rear card 230 does not. As described above for frontcard 230, an adhesive activated by some means other than heat may alsobe used. Alternatively, the rear card 230 can be fabricated withoutadhesive and adhesive may either be applied during the assembly processor a method other than adhesion may be utilized to assemble the blistercard package. In the preferred embodiment, the front of rear card 230 islaminated with a tear resistant plastic film 237 comprised of polyesteror other comparable polymers, such as polyethylene or polypropylene.After assembly, the front of rear card 230 will be hidden. Tear-stop cut236 may be added to rear card 230 in the manner described with respectto front card 201. Tear-stop cut 236 is placed one-quarter inch toone-half inch from the outer edge and is only visible from the frontview of rear card 230, as depicted in FIG. 2C. Thus, in this embodiment,the tear-stop cut is not exposed once the package is assembled.

Rear card 230 comprises perforated cut 232 forming blister panel 233that can be seen from both the front and rear of rear card 230. However,cut-score 235 may only be seen from the front of rear card 230 asdepicted in FIG. 2C. From the back of rear card 230, as shown in FIG.2D, cut-score 235 may not be visible. This may help enhance thetheft-resistance of the package since cut-score 235 is not readilyvisible to a consumer or potential thief. Cut-score 235 is shownconcentrically located within perforated cut 232; however, depending onthe material of rear card 230, implementing perforated cut 232concentrically within cut-score 235 is sometimes preferable.Additionally, the same type of cut (i.e., perforated, cut-score, ortear-stop) could be used for both the inner and outer cut. It iscontemplated that any combination or quantity of cut types and locationsmay be used without departing from the spirit of the invention.

Cut-score 235 is only visible from the front of rear card 230 because itdoes not penetrate the entire thickness of rear card 230. Rather,cut-score 235 only partially penetrates rear card 230. In contrast,blister panel 233 is cut throughout rear card 230 such that the blisterpanel 233 encircles its oval aperture 202 (FIGS. 2A and 2B) when theblister card packaging is fully assembled. The degree of perforationused to cut perforated cut 232 may be altered to vary the forcenecessary to remove blister panel 233.

Without cut-score 235, blister panel 233 is not likely to tear cleanly.Cut-score 235 along with perforated cut 232 effectively allow for aclean removal of blister panel 233. Without both cut-score 235 andperforated cut 232, blister panel 233 would not remove cleanly, thusresulting in tearing a blister panel belonging to a product that theuser does not desire to remove at that time or possibly damaging theentire blister card package. Additionally, if blister panel 233 is notremoved cleanly, blister panel 233 may separate into layers such thatone layer is removed and another layer remains attached to rear card 230or the seal. This can cause difficulties when a user attempts to pushthe product through the seal. A user may not have sufficient strength tobreak through the remaining layer of paperboard, or, if the user appliesadditional force, the force required may damage the product.

Although the preferred embodiment of the present invention uses someform of pre-applied adhesive during the construction of the blister cardpackage, it is also possible to construct the blister card package ofthe present invention without the use of pre-applied adhesives. Instead,paperboard can be purchased without pre-applied adhesive and theadhesive can be stamped onto the paperboard with a printing press suchthat adhesive is not applied to the areas slightly larger than theperimeters of blister panel 233.

In the preferred embodiment of the present invention, perforated cut 232operates in conjunction with cut-score 235, as depicted in FIG. 2E, toensure a clean tear of blister panel 233. After a user pushes on blister102 either by hand or with the help from a tool, blister panel 233 iseasily torn because blister panel 233 does not stick to the seal, andthe tear follows the path of least resistance, i.e., along cut-score235. Since perforated cut 232 and cut-score 235 are located internal tothe blister card package and are not accessible from the exterior of thepackage. These two features assist in the clean tear of blister panel233 only after blister panel 233 has been pushed either by hand or witha tool, thereby maintaining the child-resistance of the blister cardpackage.

The perforated cut 232 and cut-score 235 of the preferred embodiment ofthe present invention may be die-cut. Moreover, perforated cut 232 andcut-score 235 can be manufactured in a single step utilizing acombination of special die-cut knives. A first oval-shaped blade of theknife preferably has nicks (or a square saw tooth shaped edge) such thatthe blade creates perforations when pressed into rear card 230. A secondoval-shaped blade is preferably recessed such that it only cutspartially through rear card 230, thereby forming cut-score 235. Althoughcut-score 235 does not extend through rear card 230, the use of aspecially manufactured bi-level die, or positioning two die cuttingknives at different levels, allows the rear card to be cut in one step,thereby reducing the cost of manufacturing. Although previouslydescribed in terms of ovals or a blade having nicks, any other shapewhich functionally accomplishes the same purpose may be used withoutdeparting from the spirit of the present invention.

FIG. 3A depicts an exploded side view of front card 201, blister card100, and rear card 230 prior to assembly. Blister 102 is aligned withblister panel 233 (FIG. 2C) of front card 201 and rear card 230,respectively.

Shown in FIG. 3B is a side view of front card 201 and rear card 230after assembly. Blister 102 protrudes through oval aperture 202 of frontcard 201 (FIGS. 2A and 2B) such that it may be seen and manipulated by auser. Front card 201 is juxtaposed against rear card 230 such that base101 and seal 104 (FIG. 3A) of blister card 100 (FIG. 3A) are encasedbetween front card 201 and rear card 230. To secure the assembly, frontcard 201 and rear card 230 are preferably sealed to each other viaapplication of heat and pressure. Preferably, portions of front card 201and rear card 230 adhere to each other between blister card 100 (FIG.3A).

An additional embodiment of the present invention is illustrated in FIG.3C, which depicts an exploded side view of blister card 100, and rearcard 230 prior to assembly. Blister 102 is aligned with blister panel233 (FIG. 2C) of rear card 230.

Shown in FIG. 3D is a side view of blister card 100, and rear card 230after assembly. Blister card 100 is juxtaposed against rear card 230such that base 101 of blister card 100 is firmly adhered to rear card230. To secure the assembly, blister card 100 and rear card 230 arepreferably sealed to each other via application of heat and pressure.

To ensure proper operability of the blister card package, seal 104 ofblister card 100 (FIG. 1B) is preferably not heat sealed to panel 233 ofrear card 230 (FIGS. 2C and 2D). Thus, seal 104 does not tear when panel233 is removed. Additionally, a portion of panel 233 will not separateand remain attached to seal 104. Various manufacturing methods may beutilized to prevent adhesion of seal 104 to panel 233. One method is toavoid application of heat-activated adhesive to panel 233 or seal 104.For instance, adhesive may be applied only to front card 201 after ovalaperture 202 is cut. Alternatively, the heat-activated adhesive may beapplied to the entire front surface of rear card 230, and a speciallydesigned heat-sealing plate having voids that correspond to panel 233and seal 104 may be used to activate the adhesive only in desired areas.

Front card 201 and rear card 230 are of sufficient size to be adheredaround a blister card and to ensure child-resistance and durability.Although heat sealing is used for the preferred embodiment of thepresent invention, various other adhesion techniques may be applied suchas pressure sealing, RF sealing, dielectric sealing, ultrasonic sealing,etc. The present invention functions equally well with adhesives that donot require heat or pressure.

In an alternative embodiment, front card 201 and rear card 230 can beconstructed from a single sheet of foldable paperboard. Consequently,the sheet can be folded and blister card 100 inserted therein toassemble the blister card package. Although paperboard is preferred,various other materials may be used without departing from the scope ofthe present invention.

FIG. 4 depicts a front view of the assembled blister card packageillustrated in FIGS. 2A-3B. Blister 102 protrudes through oval aperture202. The laminated sides of the paperboard and the tear-stop cuts arenot visible since the rear card is adhered to the front card to form theblister card package. Further, when the contents of blister 102 arehidden or additional surface space for product marketing or productinformation is required by the retailer or manufacturer, contentinformation can be printed on base 101 of blister strip 100 of FIG. 1.As illustrated by FIG. 4, the content information printed on base 101 ishidden by front card 201 or rear card 230 of FIG. 3B. Yet, the contentinformation can be obtained by cutting the blister card package, tearingapart the blister card package, or by accessing the package throughpre-defined perforations.

The preferred embodiment of the present invention is shown in FIG. 5with the front card 501 extended flat and unfolded in the leftwarddirection. The rear card 230 (FIGS. 2C and 2D) may also be extended inthis direction. Fold lines 502 are implemented such that the extendedsection, left flap 503, easily folds over right flap 504. The foldedpackage may resemble the front and back covers of a book or magazine.

Left flap 503 comprises printed instructions 508 reading, “1. Push onblister to dispense.” Additional product information 509 may also beprinted on left flap 503. Pre-printed information 505 may also beincluded on right flap 504 or left flap 503 to indicate dosage number,pill type, or any other relevant information. Alternatively, pre-printedlines 506 or blank area 507 may be positioned adjacent to oval aperture202 for the user to record or log dosage taken, time of day, day ofweek, or any other useful information.

The embodiment of FIG. 5 may be folded and placed into a casingcomprising paperboard, or any other material, to protect the packagingand to prevent accidental and annoying unfolding. In a furtheralternative embodiment, left flap 503 may also comprise a blistersimilar to right flap 504. Left flap 503 and rear card 230 (FIGS. 2C and2D) may also be extended, folded, printed on, or constructed to holdmaterials to achieve the desired functionality without departing fromthe spirit of the invention.

Ultimately, the preferred embodiment of the present invention mayrequire the user to apply enough force on the blister either by hand orwith a tool to effectively tear through both the score-cut and theperforated cut. Children will still have difficulty accessing thecontent of the blister because the foil is not exposed, yet this methodis simple enough for competent individuals to understand, especiallyafter reading the instructions. There is only one step necessary tofollow in order to dispense the contents from the blister card packageand it may be summarized as follows: 1) Using a tool or your hand pushthe product through the seal.

Advantageously, paperboard can be easily printed on. Therefore, logos,text, images, patterns, designs, and other marketing material may beprinted directly on the packaging. This will make the blister cardpackage more attractive to a consumer shopping at a retail location andincrease the marketing potential of the product for the vendor. Inaddition, instructions for the product may also be printed on thepaperboard. The method of manufacturing the preferred embodiment of thepresent invention includes a single step for applying release coatingsand printed information, thus minimizing the cost of manufacturing. Inthe preferred embodiment, the printing occurs opposite the laminatedside of the paperboard. Moreover, front card 201, rear card 230, orboth, may be extended in one or more directions to provide additionalarea for printed information. Another advantage of paperboard is that itis easily written on, allowing a blister card package user to recordinformation such as when medication was administered or side effectsfelt after taking the medication. In an alternative embodiment, onesheet of paperboard may be folded to create a front card, rear card andextended side.

Another embodiment of the present invention is depicted in FIG. 6.Solid-form blister 600 comprises a two-dimensional matrix of blisters602 attached to base 601 and containing product 604. As with blisterstrip 100, the openings of blisters 602 are enclosed with seals (notshown) similar to seals 104 of FIG. 1B. Therefore, solid-form blister600 can be encased between a front and rear card in the same mannerdescribed in the aforementioned embodiments of the present invention.Additionally, solid-form blister 600 essentially operates in the samemanner as extensively described above, however has the capability tocontain a larger capacity of blisters 102 as illustrated in FIG. 6.

Several other embodiments of the present invention are adapted for usewith consumer and retail goods. FIG. 7 depicts a stiff paperboard tag700 used to house a security or audit device, such as an RFID tag,security tag, product tag, sensor, or the like. Tag 700 may comprisemultiple paperboard layers and be laminated to prevent tampering ordegradation of the product or security device contained within tag 700or tag 700 itself. It is also contemplated that tag 700 may be comprisedof other suitable materials in addition to paperboard. At least onetear-stop cut 701 is added to the perimeter of tag 700 to preventpropagation of side tears. In addition, tear-stop cut 701 may alsoreduce puncture tears initiated from the center area 704 of tag 700.Center area 704 may securely house a security device, audit tag, producttag, RFID tag, or other like object to facilitate consumer productmanagement or inventory control. The device or tag may be embedded orsecured within the front and rear cards or paperboard layers of tag 700or otherwise attached, glued, or affixed to tag 700.

Ideally, tag 700 may be placed within consumer goods and productswithout the knowledge of consumers to aid in asset management andinventory control. This way, tag 700 is not visible to consumers orpotential thieves. Alternatively, tag 700 may contain adhesive or otherattaching means, such as circular aperture 702 for tag 700 to befastened, tied, or otherwise attached to a consumer or retail productvia a product tie. Circular aperture 702 may also contain at least onetear-stop cut 703 concentric with circular aperture 702 to preventripping or pulling of tag 700 off the consumer product. For example, tag700 may be utilized to automate checkout at a retail location (with theuse of RFID tags, radio transmitters, or the like) or curb producttheft.

Another embodiment of the present invention adapted for consumerelectronics accessories is depicted in the foldable blister card of FIG.8A. Aperture 810 is cut from front card 801 conforming to the basicshape of a plastic blister 807 to be inserted between front card 801 andback card 800. Once blister 807 containing the product is inserted, backcard 800 is folded behind front card 801. The two cards are then gluedor sealed together with the application of heat and pressure, asdescribed above, thereby securing the blister to the blister card. Toopen the package, a user applies pressure on blister 807, which isattached to aperture 810. This pressure pushes the product through tothe back side removing panel 808. Cut-score 804 may be positionedslightly within perforated cut 805, allowing panel 808 to be removedfrom the package easily and cleanly when pressure is applied from thefront side. Since the tears will follow the path of least resistancearound the perimeter of the product, the product may be removed quickly,cleanly, and safely from its packaging in this manner. Safe andcontrolled removal of the product is especially important forelectronics and electronics accessories, which may be expensive andfragile. Back card 800 and front card 801 additionally may be laminatedand contain tear-stop cuts 806 along the perimeters of front card 801and back card 800 to prevent the propagation of side tears as describedin the previous embodiments.

FIG. 8B shows the assembled, folded blister package of FIG. 8A. Blister807 is preferably comprised of clear plastic for easy viewing of theproduct contained within blister 807. Printing may be located anywhereon front card 801 where convenient. Preferably, this printing describesthe product contained within blister 807, its features, cost, and anyother useful information for the consumer or retailer. Additionally, thepackage may comprise a hook aperture 809 for hanging multiple packagesat a retail location.

Another alternative embodiment is illustrated in FIGS. 9A and 9B and isadapted for mailing applications. Envelope 900 is comprised of laminatedpaperboard, cardboard, PVC, or any other suitable material. Envelope 900is laminated or embedded with plastic film 901, which could comprisebiaxial film, plastic, polyester, PVC, or any like polymer. At least onetear-stop cut 902 is ideally positioned ¼ inch to ½ inch from allperimeter edges of envelope 900 to halt the propagation of any sidetears in envelope 900. Plastic film 901 and tear-stop cut 902 willminimize any degradation of the product contained within envelope 900during shipping and processing. In addition, plastic film 901 andtear-stop cut 902 create an effective deterrent from tampering or theftof the products contained within envelope 900. The number and locationof tear-stop cut 902 can be varied as desirable. Tab edges 904 enclosethe product, which in this case may be stationary to be mailed. Tabedges 904 may contain stamped adhesive (pressure sensitive,heat-activated, or the like) or glues to assist in securing envelope 900around the product. Perforated cut 903 surrounds pull-tab 905 for easyaccess to the product after envelope 900 is sealed. In addition acut-score may be positioned slightly within or outside the perimeter ofperforated cut 903 to ensure a clean tear.

FIG. 9B shows the assembled envelope 900 of FIG. 9A. Depending on whichside of envelope 900 is laminated, tear-stop cut 902 may be visible fromthe outside of assembled envelope 900 or tear-stop cut 902 may be hiddenfrom view and only visible from inside envelope 900. Envelope 900 maycome preassembled in pre-folded form or unfolded as depicted in FIG. 9A.If envelope 900 is preassembled, the user needs only to insert a productand seal envelope 900 by folding tab edge 904 over pull-tab 905 andsecuring tab edge 904 to envelope 900. A variety of glues, adhesives, orfasteners may be used to facilitate the sealing of envelope 900.

A final embodiment of the present invention is illustrated in FIGS. 10Aand 10B. Blister 1002 houses a small consumer product 1003, such as achild's toy. Front card 1004 is preferably composed of paperboard orstiff paper, although any suitable material may be used. In addition,front card 1004 may be laminated with a plastic material to resisttearing and product tampering (as discussed above). Front card 1004contains blister aperture 1006, through which blister 1002 is placed. Arear view of front card 1004 is shown in FIG. 10B. Aperture 1006 isadapted to allow blister 1002 to pass through. Tear-stop cut 1012 ispositioned along the outer perimeter of the back of front card 1004 anda plastic film 1010 covers the card. A rear card (not shown) is attachedbehind front card 1004 to complete the consumer product packaging. Thisarrangement maintains the child resistant and theft-resistant qualitiesof the card, while at the same time making tear-stop 1012 and film 1010invisible to the consumer or user.

While the present invention has been described with reference to one ormore preferred embodiments, which embodiments have been set forth inconsiderable detail for the purposes of making a complete disclosure ofthe invention, such embodiments are merely exemplary and are notintended to be limiting or represent an exhaustive enumeration of allaspects of the invention. The scope of the invention, therefore, shallbe defined solely by the following claims. Further, it will be apparentto those of skill in the art that numerous changes may be made in suchdetails without departing from the spirit and the principles of theinvention.

1. A packaging apparatus comprising: a first panel laminated with film;a second panel laminated with film and coupled to the first panel; afirst tear-stop cut in the first panel proximate to a perimeter edge ofthe first panel; and a second tear-stop cut in the second panelproximate to a perimeter edge of the second panel; and wherein the firsttear-stop cut encircles an inner area of the first panel; and whereinthe second tear-stop cut encircles an inner area of the second panel.